Adhesive melter and method having predictive maintenance for exhaust air filter

ABSTRACT

An adhesive melter and a method for operating the adhesive melter enables predictive maintenance of an exhaust air filter used to remove pressurized air flow that delivers solid adhesive particulate from a fill system into the melter. To this end, the fill system repeatedly actuates to refill a receiving space, and a controller monitors a duration of each fill system cycle. When changes in a calculated average duration of a plurality of fill system cycles exceed a maintenance threshold, an alert is emitted at a user interface to prompt maintenance or replacement of the exhaust air filter before a complete shutdown of the fill system is caused by clogging of the exhaust air filter. Consequently, unplanned downtimes caused by clogged exhaust air filters in the adhesive melter can be minimized, regardless of any variable conditions occurring at the melter.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/953,032, filed Jul. 29, 2013, and published asU.S. Patent Application Pub. No. 2015/0027546 on Jan. 29, 2015, which isincorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to an adhesive melter used withan adhesive dispensing system, and more particularly, to controlcomponents and methods used to monitor and operate a fill systemsupplying solid adhesive to the adhesive melter.

BACKGROUND

A conventional dispensing system for supplying heated adhesive (i.e., ahot-melt adhesive dispensing system) generally includes a melter havingan inlet for receiving adhesive materials in solid or semi-solid form, aheater grid in communication with the inlet for heating and/or meltingthe adhesive materials, and an outlet in communication with the heatergrid for receiving the heated adhesive from the heated grid. The outletcommunicates with a pump for driving and controlling the dispensation ofthe heated adhesive through the outlet and to downstream equipment, suchas dispensing modules. Furthermore, conventional dispensing systemsgenerally include a controller (e.g., a processor and a memory) andinput controls electrically connected to the controller to provide auser interface with the dispensing system. The controller is incommunication with one or more of the melter, the pump, and othercomponents, such that the controller controls the dispensation of theheated adhesive.

Conventional hot-melt adhesive dispensing systems typically operate atranges of temperatures sufficient to melt the received adhesive and heatthe adhesive to an elevated application temperature prior to dispensingthe heated adhesive. In order to ensure that the demand for heatedadhesive from the gun(s) and module(s) is satisfied, the adhesivedispensing systems are designed with the capability to generate apredetermined maximum flow of molten adhesive. For example, the inlet ofthe melter communicates with a fill system operated by the controller ofthe dispensing system. In a typical arrangement, the fill systemoperates to deliver a stream of solid particulate or pelletized adhesiveusing a pressurized air flow from a bulk supply or source of the solidadhesive to the inlet of the melter whenever a receiving space (e.g.,hopper) above the heater grid requires refilling. In these arrangements,the melter also includes an exhaust outlet with a filter for dischargingthe pressurized air flow from the fill system or receiving space afterthat pressurized air flow has delivered the solid adhesive into thereceiving space. Thus, each fill system cycle requires the exhausting ofpressurized air flow out of the melter.

As readily understood, the exhaust air filter will become clogged overtime as the fill system is used. This clogging of the exhaust air filterstifles the efficient operation of the fill system because it can limitthe amount of pressurized air flow generated through the fill system andthe melter. Conventional adhesive melters and dispensing systems do notspecifically monitor the use of the exhaust air filter, so there iscurrently no known mechanism in this field to provide predictivemaintenance information to an operator regarding when the exhaust airfilter will need to be replaced. Instead, conventional systems typicallycontinue to operate until the exhaust air filter is so clogged that thefill system effectively cannot keep up with the demands for moltenadhesive from the melter, such as when the dispensing system requiresthe predetermined maximum flow of molten adhesive. Alternatively, thefill system may also stop working for other reasons such as a burst hosein the fill system or an obstruction of flow at the source of adhesive.As a result, a shutdown of the fill system occurs, which can eventuallylead to the melter running out of adhesive and shutting down as well.Therefore, the adhesive dispensing system undergoes a period ofunplanned downtime until maintenance personnel can identify the issuewith the clogged exhaust air filter (or the other issues describedabove, when applicable) and then perform appropriate maintenance, suchas a replacement of the exhaust air filter. These unplanned downtimesfor the system are undesirable and costly for operators of conventionaladhesive melters and dispensing systems.

In other pneumatic fields such as HVAC systems, air filters have beenmonitored using air flow measurement devices and/or pressure detectionsensors that provide estimates of how much air flow moves through theair filter. The air filters in these other fields are then replacedafter a set amount of air flow has passed through the air filter. Whilethis type of equipment could hypothetically be used in the conventionaladhesive melters, this equipment has not been added for multiplereasons. First, the additional air flow measurement devices and/orpressure detection sensors add additional cost to the manufacturing andmaintenance of the adhesive melter, and this additional cost mayoutweigh the benefit of attempting to provide predictive maintenanceinformation about the exhaust air filter at the adhesive melter. Second,these types of predictive maintenance based on total air flow throughthe exhaust air filter are unreliable in this context because exhaustair filters in adhesive melters are subject to highly variableconditions that may significantly alter the lifespan or total air flowthat the exhaust air filter can pass through before clogging. Thus,merely measuring the total air flow through an exhaust air filter at anadhesive melter is not a reliable method for accurately determining whenthe exhaust air filter will become clogged, and unplanned downtimes forthe adhesive melter would likely still occur.

The highly variable conditions that subject the exhaust air filters tounpredictable lifespan include the use of different adhesive materialsor variable pellet shapes/form factors with filters, as these differentmaterials or form factors can affect the amount of air flow required tomove the solid adhesive. In another example, the length of hose usedbetween the source of adhesive for the fill system and the melter mayalso affect the cycle time for a fill system and the lifespan of anexhaust air filter. In some instances, a more significant source ofunpredictability in the lifespan of exhaust air filters is the selectiveuse of powder that may be put on the solid adhesive to prevent tackinessand sticking together of the pellets or particles before delivery to thereceiving space. This powder causes more rapid clogging of the exhaustair filter at the melter, thereby shortening the lifespan of the exhaustair filter. Furthermore, the use of powder on certain batches of solidadhesive delivered to the bulk supply from which the fill system drawssolid adhesive is unpredictable because not every batch of solidadhesive may include the powder (e.g., the powder may only be used athotter times of the year when the adhesive supplier and the ambientconditions at the bulk supply may be more prone to pellets stickingtogether). The amount of powder on the adhesive that will be captured bythe exhaust air filter may also vary dramatically even between differentbatches or fill system cycles. As a result, it is currently impracticalto reliably predict when an exhaust air filter in a conventionaladhesive melter will require replacement. Furthermore, there iscurrently no known method for distinguishing reduced performance of thefill system caused by exhaust air filter clogging from reducedperformance of the fill system caused by other problems such as bursthoses or adhesive supply obstructions.

For reasons such as these, an improved adhesive melter and method ofoperation, including a control process for accurately predicting andalerting an operator when an exhaust air filter requires replacement ormaintenance, would be desirable.

SUMMARY OF THE INVENTION

According to one embodiment of the invention, a method for operating anadhesive melter enables a predictive maintenance of an exhaust airfilter used with a fill system associated with the melter. The methodincludes repeatedly actuating the fill system to perform a fill systemcycle that refills a receiving space of the melter with solid adhesiveparticulate delivered with a pressurized air flow, which must then beexhausted through the exhaust air filter. The duration of each of thefill system cycles is monitored. The method also includes calculating anaverage duration for a plurality of the fill system cycles and detectinga change in the average duration for the fill system cycles. A userinterface operatively coupled to the melter emits an alert if thedetected change exceeds a maintenance threshold that is indicative ofthe exhaust air filter becoming clogged and requiring maintenance.Accordingly, the exhaust air filter may be replaced before the cloggingstops operation of the adhesive melter.

In one aspect, the method also includes repeatedly sensing with a levelsensor at the receiving space a fill level of adhesive located withinthe receiving space. The level sensor is capable of determining when thefill level within the receiving space crosses multiple thresholdsassociated with at least a nearly empty state and a nearly full state.In this regard, operation of the fill system starts to deliver solidadhesive particulate into the receiving space when the level sensorsenses that the fill level has dropped below a refill threshold.Operation of the fill system stops when the level sensor senses that thefill level has exceeded a full fill threshold. The method also includesdetermining first and second times when the fill system starts and stopsoperating, respectively, from the readings of the level sensor. Thedifference between these first and second times provides the duration ofthe selected fill system cycle, which is then used to calculate theaverage durations that control when an alert is emitted. A controller ofthe adhesive melter performs the calculation of the average durationsand detecting a change in the average duration such that the emission ofthe alert with the user interface is initiated based only on data fromthe level sensor and the monitoring of the durations of each of the fillsystem cycles. This controller process avoids false positive indicationsof the need for exhaust air filter maintenance that may occur when usingadditional sets of data from other types of sensors or equipment.

In another aspect, detecting a change in the average duration for thefill system cycles further includes identifying a predetermined numberof most recently calculated average durations for a plurality of thefill system cycles. The predetermined number of most recently calculatedaverage durations is then statistically analyzed to determine a trendline for the most recently calculated average durations. The slope ofthis trend line corresponds to the change in the average duration forthe fill system cycles. Consequently, if the most recently calculatedaverage durations are increasing at a slope greater than the maintenancethreshold, the alert will be emitted at the user interface. The fillsystem is typically configured to shut down when the average durationfor a plurality of the fill system cycles exceeds a maximum flowthreshold that may indicate that the clogging at the exhaust air filteris preventing the fill system from keeping up with demands for moreadhesive at the receiving space. Therefore, the emission of the alert isconfigured to be initiated before the average duration exceeds themaximum flow threshold, as this will provide a period of time (e.g.,preferably a day or more) for maintenance of the exhaust air filterbefore shut down of the fill system would occur (and a possible shutdown of the melter caused by running out of adhesive) due to clogging ofthe exhaust air filter. The alert can then continue to be emitted untilmaintenance is performed on the exhaust air filter or the fill systemshuts down.

To prevent statistical outliers from affecting the analysis of theaverage durations for fill system cycles, the method includes additionalsteps for identifying and removing such statistical outliers not causedby clogging of the exhaust air filter. For example, the method mayfurther include statistically analyzing the duration of each of the fillsystem cycles to identify the individual data outliers that indicate achange in the average duration for reasons unrelated to exhaust airfilter clogging (e.g., a burst hose in the fill system, an obstructionin the adhesive source, a change in adhesive material used or the lengthof hose in the fill system). These individual data outliers are thendiscarded before calculating the average duration and detecting a changein the average duration for the fill system cycles. In another example,the duration for each of the fill system cycles may be evaluated untilthe average duration stabilizes after an initial time period followingmaintenance or replacement of the exhaust air filter. All data fordurations of fill system cycles during this initial time period are thendiscarded before detecting a change in the average duration for the fillsystem cycles. As such, data outliers caused by events unrelated togradual filter clogging and data outliers known to occur at thebeginning of a filter's lifespan are not used to control when the alertis emitted to prompt maintenance for the exhaust air filter.

In another embodiment, an adhesive melter is configured to provide thepredictive maintenance for an exhaust air filter to avoid unplanned shutdowns of the fill system. The melter includes a receiving spaceconfigured to receive a supply of solid adhesive particulate that is tobe melted by a heater unit, a fill system that performs fill systemcycles that refill the receiving space, and the exhaust air filter whichcommunicates with the fill system and the receiving space to exhaustpressurized air flow that carries the solid adhesive particulate intothe receiving space. The melter also includes a controller that worksduring operation of the melter to repeatedly actuate the fill system, tomonitor the duration of each fill system cycle, to calculate an averageduration for a plurality of the fill system cycles, to detect a changein the average duration for the fill system cycles, and to emit an alertwith a user interface if the detected change exceeds a maintenancethreshold indicative of the exhaust air filter becoming clogged. As aresult, maintenance or repair of the clogged exhaust air filter may beconducted before the clogging causes a shutdown of the fill system.

The adhesive melter also includes a level sensor located at thereceiving space for repeatedly sensing a fill level of adhesive locatedwithin the receiving space. The level sensor, in one embodiment,includes a plate element with an electrically driven electrode and aground electrode such that the level sensor measures a dielectriccapacitance of air and adhesive acting as dielectric between the drivenand ground electrodes. The dielectric capacitance varies with the filllevel of the adhesive, so the level sensor can monitor when the filllevel passes certain thresholds such as a refill threshold for startingoperation of the fill system, or a full fill threshold for stoppingoperation of the fill system. The information from the level sensor maybe used to determine the start and stop times and total durations oftime for each fill system cycle. The controller actuates the emission ofthe alert based solely on data received from the level sensor, therebyavoiding false positive alerts that may occur when additional data isused for predictive maintenance.

These and other objects and advantages of the invention will become morereadily apparent during the following detailed description taken inconjunction with the drawings herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate an embodiment of the inventionand, together with a general description of the invention given above,and the detailed description of the embodiment given below, serve toexplain the principles of the invention.

FIG. 1 is a schematic block diagram view of an adhesive dispensingsystem including an adhesive melter and a fill system according to oneembodiment of the current invention.

FIG. 2 is a cross-sectional front view of the adhesive melter of FIG. 1,illustrating additional features such as a level sensor in a receivingspace and a cyclonic separator unit defining the inlet and the exhaustfor pressurized air flow to and from the adhesive melter.

FIG. 3 is a detailed cross-sectional front view of the receiving spaceand cyclonic separator unit of FIG. 2, with an exemplary flow ofpressurized air and solid adhesive pellets shown entering the melter andexiting through an exhaust air filter.

FIG. 4 is a flowchart describing a sequence of operational stepsperformed by the fill system and a controller connected to the adhesivemelter of FIG. 1, to thereby provide predictive maintenance alerts forclogging of the exhaust air filter of FIG. 3.

FIG. 5 is a time graph showing trends of an average daily fill timeobtained using the sequence of operational steps of FIG. 4, to explainhow the predictive maintenance alerts are triggered.

FIG. 6 is a schematic representation of a user interface of the adhesivedispensing system of FIG. 1, showing an exemplary maintenance alert forreplacing the exhaust air filter.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring to FIGS. 1 through 6, an adhesive dispensing system 10 inaccordance with one embodiment of the invention is shown, the system 10including an adhesive melter 12 configured to perform a method forpredictive maintenance of an exhaust air filter 14 associated with theadhesive melter 12. The adhesive melter 12 operates to monitor aduration of fill system cycles used to refill the adhesive melter 12with solid adhesive particulate, and these durations of fill systemcycles are then used to determine whether an alert should be emittedregarding the immediate need for maintenance or replacement of theexhaust air filter 14. When an alert is emitted, such as on a userinterface 16 operatively connected to the adhesive melter 12, theoperator of the adhesive dispensing system 10 will be provided with aperiod of time to conduct maintenance on the exhaust air filter 14before the exhaust air filter 14 becomes so clogged that the adhesivemelter 12 cannot function properly. Accordingly, unplanned downtime forthe dispensing system 10 that is caused by clogging of the exhaust airfilter 14 is minimized or avoided altogether. Advantageously, theadhesive melter 12 and method described in further detail below operateto reliably provide predictive maintenance regardless of variableoperating conditions at the adhesive melter 12, including, but notlimited to, selective powdering of the adhesive to prevent tackiness andchanges in adhesive form factor.

Before describing the detailed operation and functionality associatedwith the method for providing predictive maintenance (see discussionpertaining to FIGS. 4 and 5, below), a description of the exemplaryadhesive dispensing system 10 and adhesive melter 12 that perform thisprocess will be helpful to understanding the functionality. Withparticular reference to FIG. 1, the adhesive melter 12 of the adhesivedispensing system 10 includes a receiving space 20 (also referred to asa “hopper” in some embodiments), a level sensor 22, a heater unit 24receiving adhesive from the receiving space 20, and a reservoir 26receiving adhesive melted and heated by the heater unit 24. The adhesivemelter 12 of this embodiment also includes a fill system 28 operable todeliver solid or semi-solid adhesive particulate to the receiving space20 using a pressurized air flow to refill the receiving space 20 whennecessary. The adhesive melter 12 therefore also includes the exhaustair filter 14, through which the pressurized air flow from the fillsystem 28 and the receiving space 20 is discharged from the adhesivemelter 12. This exhaust air filter 14 requires maintenance orreplacement over time as a result of clogging, and the adhesive melter12 and methods described below advantageously enable predictivemaintenance of this exhaust air filter 14. It will be understood thatthe adhesive melter 12 may include more or fewer elements in otherembodiments, including the other elements shown outside the dashed linebox representing the adhesive melter 12 in FIG. 1, without departingfrom the scope of the invention.

As shown in FIG. 1, the adhesive melter 12 further includes a pump 32configured to deliver heated adhesive from the reservoir 26 to adispenser gun 34 or module. As the dispenser gun 34 operates todischarge melted adhesive from the dispensing system 10, adhesivematerial is removed from the adhesive melter 12, and this eventuallyleads to a fill system cycle operated by the fill system 28 to refillthe receiving space 20 with more solid adhesive particulate. These fillsystem cycles are monitored to determine when an alert should beprovided on the user interface 16 regarding necessary maintenance for aclogged exhaust air filter 14. It will be understood that the pump 32,fill system 28, and/or other elements may be separated from the melter12 in some embodiments without departing from the scope of theinvention.

The adhesive dispensing system 10 also includes a controller 36operatively connected to one or more of the fill system 28, the levelsensor 22, the heater unit 24, the pump 32, and the dispenser gun 34.The controller 36 includes a processor and a memory (not shown), andalso program code resident in the memory and configured to be executedby the processor. As described in further detail below, the program codeoperates to monitor fill levels of adhesive in the receiving space 20,actuate refilling operations by the fill system 28, and then monitorthese fill system cycles to determine whether an alert should beprovided to the operator to prompt repair or replacement of the exhaustair filter 14. To this end, the controller 36 includes or is connectedto a timer 38 configured to measure the elapsed time for fill systemcycles. The timer 38 may be a separate time measurement device or aclock device configured to provide the current time to the controller 36in embodiments where the timer 38 is not incorporated into thecontroller 36. The controller 36 then communicates with the userinterface 16, which may be incorporated as part of the adhesive melter12 or unrelated to the adhesive melter 12 in other embodiments, toinitiate the alert for predictive maintenance. It will be understoodthat the predictive maintenance methods and functionality describedbelow may be used with other types of dispensing systems and meltershaving a different arrangement of components, without departing from thescope of this invention.

The exemplary embodiment of the adhesive melter 12 shown schematicallyin FIG. 1 is illustrated in further detail in FIGS. 2 and 3. Many of thecomponents of the adhesive melter 12 are also described in co-pendingU.S. patent application Ser. No. 13/799,622 to Clark et al., entitled“Adhesive Dispensing Device having Optimized Reservoir and CapacitiveLevel Sensor,” the disclosure of which is hereby incorporated byreference herein in its entirety. Similarly, the specific flows of solidadhesive particulate and pressurized air flow shown in these FIGS. isalso described in co-pending U.S. patent application Ser. No. 13/799,788to Chau et al., entitled “Adhesive Dispensing Device having OptimizedCyclonic Separator Unit,” the disclosure of which is hereby incorporatedby reference herein in its entirety. The following descriptionsummarizes these more detailed disclosures with a particular emphasis onthe structural components used to perform the predictive maintenance ofthe exhaust air filter 14.

With reference to FIG. 2, the receiving space 20 or hopper is mounteddirectly above the heater unit 24, which is in turn mounted directlyabove the reservoir 26. Consequently, a gravity-driven flow of adhesiveis provided between the receiving space 20 where solid adhesiveparticulate is initially delivered and the reservoir 26 thatcommunicates heated and melted adhesive to the pump 32 (not shown inFIGS. 2 and 3). The adhesive melter 12 is configured to operate filledwith adhesive material so that the heater unit 24 is not exposed to openair for extended periods of time, which could lead to overheating of theheater unit 24 and any remaining adhesive in the melter 12. Morespecifically, the adhesive melter 12 is filled during normal operationsuch that the heater unit 24 and the reservoir 26 are completely filledwith adhesive and the receiving space 20 is at least partially filledwith solid or semi-solid adhesive. Therefore, the fill level of theadhesive inside the melter 12 is measured by the level sensor 22, whichis located at the receiving space 20. As the fill level lowers withinthe receiving space 20, the controller 36 receives this information fromthe level sensor 22 and then actuates the fill system 28 to perform afill system cycle and deliver solid adhesive particulate to refill thereceiving space 20. This process, including sensing the fill level inthe receiving space 20 and then actuating refills with the fill system28, repeats during normal operation of the melter 12 and is the basisfor performing the predictive maintenance of the exhaust air filter 14.

The level sensor 22 of the exemplary embodiment includes a capacitivelevel sensor in the form of a plate element 42 mounted along one of theperipheral sidewalls 44 of the receiving space 20. The plate element 42includes a driven electrode 46 and a ground electrode 48 that is coupledto one or more of the sidewalls 44 of the receiving space 20 with platefasteners 50 as shown. Therefore, the sidewalls 44 of the receivingspace 20 also act as a portion of the ground electrode for the levelsensor 22. The level sensor 22 determines the fill level of adhesivematerial in the receiving space 20 by detecting with the plate element42 where the capacitance level changes between the driven electrode 46and the ground electrode 48. To this end, open space or air in thereceiving space 20 provides a different capacitance than the adhesivematerial in the receiving space 20. The level sensor 22 is connectedwith the controller 36 to provide information corresponding to the filllevel passing multiple threshold levels in the receiving space (e.g., arefill threshold level where refill of the receiving space 20 should beactuated immediately and a full fill threshold level when the receivingspace 20 has been sufficiently filled by the fill system 28).Alternatively, the single level sensor 22 shown in FIGS. 2 and 3 may bereplaced by multiple smaller level sensors (not shown) operable to sensewhen the fill level in the receiving space 20 passes the relevantthresholds. Accordingly, the level sensor 22 is capable of providingsignals to the controller 36 to start and stop fill system cycles withthe fill system 28 to keep the receiving space 20 from becoming tooempty or overfilled, and these signals can also be used to determinepredictive maintenance for the exhaust air filter 14, as described infurther detail below.

In this regard, the controller 36 is operatively connected to orincludes the timer 38, which applies a time stamp to each instance whenthe level sensor 22 senses that the fill level within the receivingspace 20 drops below the refill threshold or exceeds the full fillthreshold. For each fill system cycle actuated by the controller 36, thedifference between the time when the fill level drops below the refillthreshold and the time when the fill level exceeds the full fillthreshold is indicative of the duration for the fill system cycleoperated by the fill system 28. As a result, the level sensor 22 andtimer 38 provide sufficient data for the controller 36 to record theduration of each fill system cycle. This data is then collected togetherand analyzed per the methodology described below to determine when theexhaust air filter 14 is becoming clogged and requires maintenance orreplacement. This functionality of the controller 36 uses informationthat is already required to keep the receiving space 20 and melter 12filled with sufficient adhesive during operation, so no additional airflow or pressure sensors are necessary within the adhesive melter 12.

As shown in FIGS. 2 and 3, a cyclonic separator unit 52 may be mountedon top of the receiving space 20 in the exemplary embodiment of theadhesive melter 12. The cyclonic separator unit 52 receives adhesivepellets 54 or other solid adhesive particulate driven by a pressurizedair flow through an inlet hose (not shown) leading to the fill system28. To this end, the inlet hose connects to a tangential inlet pipe 56that communicates with a generally cylindrical pipe 58 extending fromthe tangential inlet pipe 56 to an opening 60 at the top of thereceiving space 20. The generally cylindrical pipe 58 may include amounting plate 62 configured to be coupled to the sidewalls 44 of thereceiving space 20 using bolt fasteners 64 or other connecting elements,as shown. Consequently, the incoming flow of adhesive pellets 54 andpressurized air flow is directed to spiral downwardly through thegenerally cylindrical pipe 58 towards the receiving space 20 as shown byfirst flow arrows 66 in FIG. 3. It will be understood that the cyclonicseparator unit 52 decelerates the speed of the pressurized air flow andthe incoming adhesive pellets 54 before those adhesive pellets 54 aredelivered into the receiving space 20, and this reduction in speedminimizes any splashing of liquid adhesive that may be within thereceiving space 20. The receiving space 20 is sealed from theenvironment upstream from the heater unit 24 but for the connection tothe cyclonic separator unit 52, so the cyclonic separator unit 52 alsoincludes an exhaust pipe 68 proximate to the tangential inlet pipe 56for removing the pressurized air flow from the receiving space 20.

To this end, the tangential inlet pipe 56 defines the inlet into thereceiving space 20, and the exhaust pipe 68 defines the outlet from thereceiving space 20. The exhaust pipe 68 therefore defines an internalpassage 70 sized to receive the exhaust air filter 14 used with theexemplary embodiment of the adhesive melter 12. The incoming flow of airand pellets 54 shown by the first flow arrows 56 is separated at or nearthe receiving space 20 such that the adhesive pellets 54 drop into thereceiving space 20 as shown by second flow arrows 72 and the pressurizedair flow reverses direction and flows upwardly within the generallycylindrical pipe 58 and through the exhaust pipe 68 and exhaust airfilter 14 back to the surrounding environment, as shown by third flowarrows 74. In this regard, all of the pressurized air flow exiting thereceiving space 20 and the adhesive melter 12 passes through the exhaustair filter 14 such that any adhesive vapors, powder, or othercontaminants may be removed from the outgoing exhaust flow.

The amount of contaminants that must be removed with the exhaust airfilter 14 can vary significantly between fill system cycles as a resultof various factors, including the form factor or shape defined by thesolid adhesive particulate and whether the solid adhesive particulate ispowdered to avoid sticking together upstream from the fill system 28.The operator of the adhesive melter 12 likely has very little or nocontrol over these varying operating conditions, so it is difficult topredict how quickly the exhaust air filter 14 will clog over time.However, the predictive maintenance enabled by the process describedbelow automatically adjusts to the varying operating conditions, therebyovercoming the problems previously encountered when using exhaust airfilters 14 that unexpectedly clog and cause unplanned downtime for theadhesive melter 12. More particularly, an alert is provided on a userinterface 16, either located at the melter 12 or some other convenientlocation, to prompt the operator to repair or replace the exhaust airfilter 14 before the clogging causes an unplanned shutdown of the fillsystem 28 (and also potentially a later shutdown of the melter 12).

To summarize the functionality, the adhesive melter 12 operates byhaving the controller 36 actuate heating and melting of adhesive with atleast one heater element 80 located in sidewalls 82 and/or partitions 84of the heater unit 24 and with at least one heater element 86 located insidewalls 88 and/or fins/partitions 90 of the reservoir 26. As theheated adhesive is drawn out of the reservoir 26 by the pump 32, thelevel sensor 22 detects the need to refill the receiving space 20 andthe controller 36 actuates the fill system 28 to provide more solidadhesive particulate through the cyclonic separator unit 52. Thepressurized air flow generated during a fill system cycle is thenexhausted through the cyclonic separator unit 52 and the exhaust airfilter 14. The controller 36 uses information from the level sensor 22and the timer 38 to statistically analyze the data regarding fill systemcycle durations and thereby determine any change in the average durationfor fill system cycles, which provides the information necessary todetermine when maintenance of the exhaust air filter 14 will berequired. For example, the “change” that is determined may includechanges in duration over multiple cycles or the rate of change of suchchanges in duration (e.g., a second derivative analysis) in someembodiments. One specific method programmed into the controller 36 forperforming this analysis and predictive maintenance is described infurther detail below, but it will be understood that the exemplaryembodiment of the adhesive melter 12 shown in FIGS. 1 through 3 may bemodified in other embodiments without departing from the scope of theinvention.

Now turning to FIG. 4, the controller 36 is configured to perform theseries of operations defining the predictive maintenance processaccording to one embodiment of the invention, this series of operationsbeing labeled with reference number 400 in the Figure. The series ofoperations begins by starting the timer 38 at a time t=0 (block 402).This variable t will be used to time stamp the beginning and end of fillsystem cycles as briefly described above. The controller 36 operates themelter 12 to provide hot melt adhesive to the remainder of the adhesivedispensing system 10 (block 404). This adhesive melter operationincludes the heating and melting of solid particulate adhesive as theheated adhesive is removed using the pump 32 or the dispenser gun 34.After a period of operation, the fill level of adhesive within thereceiving space 20 will drop below a refill threshold that indicates arefill is necessary to avoid uncovering the heater unit 24. Once thelevel sensor 22 detects that the fill level within the receiving space20 has dropped below this refill threshold, the controller 36 actuatesthe fill system 28 to perform a fill system cycle and thereby refill thereceiving space 20 with more adhesive (block 406). The fill system 28will deliver adhesive pellets 54 in a pressurized air flow into thereceiving space 20 as described in detail above.

The fill system 28 is configured to continue delivering adhesive pellets54 and pressurized air flow until one of two conditions occur: the fillsystem 28 has been running for a maximum cycle time (e.g., 10 seconds insome embodiments), or the level sensor 22 detects that the receivingspace 20 is filled. To this end, the level sensor 22 also senses whenthe fill level of adhesive within the receiving space 20 exceeds a fullfill threshold, at which point the controller 36 knows the receivingspace 20 is filled and the operation of the fill system 28 can bestopped. While the controller 36 has been actuating the fill systemcycle to start and stop, the timer 38 has been applying a time stampbased on the time t when the level sensor 22 detected the fill leveldropping below the refill threshold (i.e., when the fill system cyclestarted) and the time t when the level sensor 22 detected the fill levelexceeding the full fill threshold (i.e., when the fill system cyclestopped). As discussed above, this example of a running timer 38 mayinstead be replaced with a timing device internal to the controller 36or a global clock that provides current time information in otherembodiments of the invention. The controller 36 receives these data fromthe timer 38 and determines an elapsed cycle time or “duration” for thefill system cycle, this elapsed cycle time being the difference betweenthese time values monitored by the timer 38 (block 408). The fill systemcycle and its duration are stored as a data point in the memoryassociated with the controller 36, and the specific time t when the fillsystem cycle was operated may also be stored as a part of this datapoint (block 410). Therefore, over the course of operation, these stepsat blocks 406 through 410 can be reused to monitor and store theduration of each fill system cycle.

In the exemplary embodiment shown in FIG. 4, the controller 36 may beoperated in a plurality of modes, including, but not limited to, astartup mode and a monitoring mode. The startup mode is used tocalibrate the readings for fill system cycle durations during an initialperiod of time such as a few days or a week following the installationof a new exhaust air filter 14. This startup mode ensures that the fillsystem cycle durations have stabilized and also ensures that sufficientdata is collected for the analysis described below. The monitoring modefollows the startup mode and includes this analysis of the fill systemcycle durations. It will be understood that the controller 36 mayperform the foregoing and following functions without specificallyoperating in distinct modes such as these in other embodiments, butthese modes will assist in understanding the operation of the adhesivemelter 12.

Thus, in the exemplary embodiment the controller 36 next determineswhether the startup mode is active (block 412). If the startup mode isactive, then the controller 36 determines a total number of fill systemcycles that have been run during the startup mode (block 414). Thistotal number should be equivalent to the number of data points storedduring this mode. The controller 36 determines if this number of fillsystem cycles provides sufficient data to generate an average durationfor the fill system cycles (block 416). This determination may be basedon prior testing that determines how many fill system cycles generallyneed to be performed before the cycle duration stabilizes from theinitial unpredictability caused early in the lifespan of the exhaust airfilter 14. For example, the first few days of fill system cycles may berequired before a reliable average duration for a plurality of the fillsystem cycles can be calculated. This sufficient data may be apredetermined set number of data points or a set period of time t thatthe melter 12 has to be operated during the startup mode. Thus, ifsufficient data has not been collected at step 416, the process returnsto block 406 to actuate the fill system 28 again once the level sensor22 detects that a refill of the receiving space 20 is required. Thiscollection of data repeats until sufficient data has been collected.

Once the controller 36 determines at step 416 that sufficient data hasbeen collected during the startup mode, the controller 36 proceeds toremove any data outliers that fall outside a predetermined deviation(such as one or more standard deviations) from the remainder of thestored data (block 418). This identification of data outliers isconducted using known statistical analysis methods such as thecalculation of a standard deviation and a determination of which datapoints fall outside the standard deviation. In addition to statisticaloutliers caused by occurrences unrelated to filter clogging (e.g.,caused by a burst hose in the fill system, an obstruction in theadhesive source, a change in adhesive material used or the length ofhose in the fill system), a predetermined number of the initial fillsystem cycles may also be removed during this process to avoid the useof unreliable data known to occur during the first few days of operationwith a new exhaust air filter 14. In another example, a series ofconsecutive fill system cycles having maximum duration may be discardedbecause this likely indicates an initial filling of the melter 12 froman empty condition. The statistical analysis performed on the data instep 418 is programmed and tailored to leave only those data pointswhich will be reliable and helpful in determining the gradual cloggingof the exhaust air filter 14.

With the remaining data from the startup mode, the controller 36calculates the average duration for a plurality of fill system cycles(block 420). This average duration represents a baseline that willchange over time as the exhaust air filter 14 becomes more clogged, asthe fill system 28 will not be able to generate and exhaust as muchpressurized air flow as the exhaust air filter 14 becomes more clogged.To this end, the average duration for the plurality of fill systemcycles is ready to be analyzed over time and further fill system cyclesto determine when the clogging of the exhaust air filter 14 is adverselyaffecting the operation of the fill system cycles. Following thisinitial calculation of the average duration, the controller 36 ends thestartup mode and begins the monitoring mode (block 422), at least inthose embodiments having distinct modes of operation. The controller 36then returns to step 402 to reset the timer 38 back to zero for themonitoring mode.

While in the monitoring mode, the controller 36 will determine at step412 (following another detection and storage of an elapsed cycle timefor a fill system cycle) that the startup mode is not active. In thiscircumstance, the controller 36 proceeds by identifying a group of thestored data points for testing whether a significant change in theaverage duration for fill system cycles has occurred (block 424). Thisidentified group of data may include a predetermined number of the mostrecently stored data in the memory, for example. In other words, thecontroller 36 may have access to monitored durations for fill systemcycles extending back to the beginning of use for the exhaust air filter14, but trends or changes in the average duration for fill system cycleswill be best revealed when analyzing only a set number of more recentdata. The identification of which data to use in the following analysismay be modified in other embodiments as well depending on thepreferences of the operator.

Once the group of data for the test has been identified, the controller36 removes any data outliers that fall outside a predetermined deviationfrom the remainder of the group of data (block 426). This removaltypically follows similar statistical analysis rules as those describedabove with reference to step 418. In another example of removing suchdata outliers, the data may indicate a change from a plurality of fillsystem cycles with a stable average duration about 3.0 seconds toanother plurality of fill system cycles with a stable average durationof about 5.0 seconds. Such a change is likely caused by factorsunrelated to filter clogging, including a change in hose length betweenan adhesive source and the melter 12 or a change in adhesive materialused, so the statistical analysis would disregard the older fill systemcycles with the stable average duration of about 3.0 seconds in step 426for this example. The controller 36 then statistically analyzes theremaining data and formulates a trend line for the data (block 428). Theformulation of a “trend line” is described for exemplary purposes only,as the controller 36 does not necessarily need to plot all of the dataonto a graph to identify any trends in the duration data over time. Ifthe controller 36 did produce a plot of the data on a graph, a sample ofsuch a plotting of data (without a trend line) is shown in FIG. 5, whichis discussed in further detail below. The trend line defines a slopethat will correspond to “a change” in the average duration of fillsystem cycles over the selected predetermined number of most recentlyperformed fill system cycles. This detected “change” could be thegeneral increase of average duration from cycle to cycle, the rate ofchange of the changing average duration (e.g., a second derivativeanalysis), or some similar indicator of hampered performance by filterclogging. The specific statistical analysis chosen for step 428 may bechosen based on the desires of the operator or end user. Regardless ofhow the “change” is defined, the controller 36 calculates the slope ofthe trend line relative to the average duration and sets this slope as avariable Δ (block 430).

The controller 36 then determines whether the variable Δ is greater thanor equal to a predetermined maintenance threshold value that indicatesclogging of the exhaust air filter 14 and an imminent need to replace orperform maintenance on the exhaust air filter 14 (block 432). Thepredetermined threshold value is set based on a plurality of factors,such as previous test data that shows the typical increase in fillsystem cycle duration over time. This maintenance threshold also dependson the type of statistical analysis being performed to identify thechange in the durations of fill system cycles. For example, the changein the average duration may be required to exceed a 4-5% increase perfill system cycle in one embodiment, although it will be understood thata slope or variable Δ of greater than 1% per fill system cycle may besufficient to determine significant filter clogging. Regardless of whatcriteria is used to set the predetermined threshold value, the detectionof whether the variable Δ exceeds this value is tailored to provide anearly indication of when the exhaust air filter 14 requires maintenance,thereby identifying a potential problem in advance of an automaticshutdown of the fill system 28.

If the variable Δ does not exceed the predetermined threshold value atstep 432, then the controller 36 returns to step 406 to begin anotherfill system cycle when a refill is again required in the receiving space20. The process of monitoring the duration of the next fill system cycleand detecting a change in the average duration of a plurality of fillsystem cycles repeats until clogging at the exhaust air filter 14 isdetermined by this process. In this regard, if the variable Δ doesexceed the predetermined threshold value at step 432, then thecontroller 36 initiates an alert 522 on a display screen 520 of the userinterface 16 (see FIG. 6 and discussion below) that informs an operatorof the need to replace the exhaust air filter 14 (block 434). Generally,the alert 522 is maintained until the clogging of the exhaust air filter14 causes an automatic shutdown of the fill system 28 or the operatorconducts maintenance on the exhaust air filter 14, typically byreplacement of the exhaust air filter 14. Once the maintenance occurs,the controller 36 ends the monitoring mode and begins the startup modeagain (block 436), and then returns to step 402 to reset the timer 38 tozero for the new startup mode. This process continuously cycles betweenthe modes as each exhaust air filter 14 is installed and used to thepoint where the clogging significantly affects the ability of the fillsystem 28 to sufficiently refill the adhesive melter 12.

Accordingly, the series of operations included in the process 400 shownin FIG. 4 is one embodiment that enables predictive maintenance alertsto be generated for clogging of the exhaust air filter 14. Furthermore,these predictive maintenance alerts are based solely on the timemeasured for the plurality of fill system cycles operated by the fillsystem 28, as this information is sufficient by itself to reliablydetermine when the exhaust air filter 14 is clogging to the extent ofdeteriorating performance for the fill system 28. Therefore, additionalsensors do not need to be added to the adhesive melter 12, and in fact,such additional sensors would be undesirable because the analysis usingthose sensors may lead to more false positive tests for clogging (e.g.,resulting in filters being replaced before being clogged at the end of alifespan). The information provided by the level sensor 22 and the timer38 is sufficient for the controller 36 to make a reliable determinationregarding when the exhaust air filter 14 is becoming clogged and needsreplacement. It will be understood that the process 400 described abovemay be modified in several aspects without departing from the scope ofthe invention, so long as the adhesive melter 12 continues to providethe predictive maintenance alerts.

A sample representation of the data collected during the beneficialoperation of the adhesive melter 12, while using the series ofoperations shown in FIG. 4 is illustrated in graphical form in FIG. 5.To this end, FIG. 5 illustrates a graphical plot 500 of average dailyfill times (shown as daily averages rather than raw data on each fillsystem cycle, for simplicity) against the number of days since theexhaust air filter 14 was most recently replaced, which corresponds tothe current lifespan of the exhaust air filter 14. These average dailyfill times provide a typical series of data that may be encountered whenperforming the analysis process with the controller 36 as describedabove. As described above, the controller 36 does not necessarilygenerate such a plot or graph during the statistical analysis, but thisplot is helpful in understanding how the statistical analysis identifiestrends that appear to be caused by filter clogging. It will beunderstood that these data points are provided from sample lab testingfor descriptive purposes only and shall not be deemed to limit theinvention in any substantial way.

As shown in FIG. 5, the plot 500 of the average daily fill times beginswith a series of average durations that are relatively high (about 5-6seconds) at point 502. Then average durations then drop to a relativelystable value over the next few days of about 2-3 seconds. This initialhigher set of average durations are a result of the startup period asdescribed above, and these data should be removed from the analysis whenthe controller 36 begins monitoring whether the average durations arechanging in such a way to indicate filter clogging. Although the averagedaily fill times change from day to day, the average durationscalculated by the controller 36 remain largely within the 2-3 secondwindow over a period of about 60 days. One exception is a spike at point504, but this data point 504 stands out as a statistical outlier whenreviewing the plot 500 of data as a whole. Therefore, using thestatistical analysis described above, the data point at 504 would beeliminated from the repeated evaluation of whether the fill systemcycles are changing in duration. More specifically, the data point 504is likely an aberration caused by factors other than clogging of theexhaust air filter 14, as such clogging over time does not tend to havean immediate effect like that data point 504 would show. For example,the spike in duration may be caused by a hose bursting at the fillsystem 28 or a temporary running out or obstruction of adhesive at thesource feeding the fill system 28 (these types of events may also shutdown the fill system 28, but not for reasons related to filterclogging). As such, the controller 36 will determine that the change inaverage durations for fill system cycles is not significant in thisfirst 60 day window.

However, after day 60 the average daily fill times begin to increaserelatively rapidly over the remainder of the lifespan of the exhaust airfilter 14. After a few consecutive increases in the average duration forthe fill system cycles, such as at point 506, the variable Δ for theslope of the trend line would exceed the corresponding predeterminedthreshold value as a result of the deteriorating performance shown inthe average daily fill times. In the example shown in FIG. 5, a smallseries of 3-5 most recent average daily fill times may be considered inthe detection of changing average durations. However, it will beunderstood that the average duration may be calculated after each fillsystem cycle, and a higher number (e.g., when the adhesive melter 12performs 20 refills per hour or more) of these average durations couldbe analyzed in other embodiments of the invention to detect a sufficientincrease or change in average durations. In the example shown in FIG. 5,the slope or variable Δ that the controller 36 may test for is anincrease of more than 1 second per day in the average daily durationsover 3 or more days. Such a predetermined threshold will causeinitiation of the alert 522 at a relatively early point like 506 in theclogging of the exhaust air filter 14, and this would provide a periodof a few days before the clogging led to an average daily fill time ofover 10 seconds at data point 508, at which point an automatic shutdownof the fill system 28 would occur. To this end, the sample data shown inFIG. 5 would provide up to 5 days of alert or notification to change theexhaust air filter 14 before an unplanned downtime would occur. Thattime period advantageously provides predictive maintenance for theexhaust air filter 14 in a reliable and repeatable manner.

With reference to FIG. 6, the user interface 16 according to theexemplary embodiment of the adhesive dispensing system 10 is shown. Asdiscussed above, this user interface 16 may include a display screen 520located at the adhesive melter 12 itself or at some other convenientlocation such as a control room. The user interface 16 will providemultiple pieces of information pertaining to operational data andsettings being used for the components of the melter 12 and thedispensing system 10, so this is also a convenient location for thealert 522 to be displayed to an operator. As shown in FIG. 6, the alert522 is tailored to draw the immediate attention of the operator, and thealert 522 could be presented in a different font, color, or with aflashing display to further enhance the visibility of the alert 522. Inaddition, an audible signal may also be emitted if desired. An operatorinteracting with the display screen 520 will readily understand from theclear statement of the alert 522 what maintenance needs to occur. Tothis end, the maintenance alerts for the exhaust air filter 14 may beformatting similarly to other component maintenance alerts that occurafter a certain period of operational cycles (such as for a pump 32) ora similar monitoring metric. The process and dispensing system 10described above advantageously provide predictive maintenance for theseexhaust air filters 14, which is a feature not provided in conventionaladhesive systems.

In addition, the predictive maintenance enabled by the process anddispensing system 10 of this invention operates reliably regardless ofchanging operational conditions present in most adhesive dispensingsystems 10. More particularly, during a hotter time of year when morepowdering of solid adhesive particulate is done by suppliers, thelifespan of the exhaust air filter 14 will shorten significantly, but itwill still exhibit a period of time where the average durations of fillsystem cycles stays about the same followed by a period of time with adiscernable steady increase in the average durations of fill systemcycles as the exhaust air filter 14 becomes more clogged. Therefore, nomatter whether the total lifespan of the exhaust air filter 14 is 30days or 90 days, the increase in average durations for fill systemcycles will be detected and an alert emitted in advance of the automaticshutdown of the fill system 28 caused by excessive clogging of theexhaust air filter 14. The adhesive dispensing system 10 thereforeenables predictive maintenance of exhaust air filters 14 that minimizesor eliminates unplanned downtime that are caused by clogging of thesefilters in conventional systems.

While the present invention has been illustrated by a description ofseveral embodiments, and while those embodiments have been described inconsiderable detail, there is no intention to restrict, or in any waylimit, the scope of the appended claims to such detail. Additionaladvantages and modifications will readily appear to those skilled in theart. Therefore, the invention in its broadest aspects is not limited tothe specific details shown and described. The various features disclosedherein may be used in any combination necessary or desired for aparticular application. Consequently, departures may be made from thedetails described herein without departing from the spirit and scope ofthe claims which follow.

What is claimed is:
 1. An adhesive melter, comprising: a receiving spaceconfigured to receive a supply of solid adhesive particulate to bemelted by a heater unit; a fill system coupled to said receiving spaceand performing fill system cycles that refill said receiving space withsolid adhesive particulate delivered with a pressurized air flow; anexhaust air filter communicating with said fill system and saidreceiving space, said exhaust air filter exhausting the pressurized airflow from said receiving space during fill system cycles; and acontroller operatively coupled to said fill system and configured to:repeatedly actuate said fill system, monitor a duration of each fillsystem cycle performed by said fill system, calculate an averageduration for a plurality of the fill system cycles, detect a change inthe average duration for the fill system cycles, and generate a signalif the detected change exceeds a maintenance threshold indicative ofsaid exhaust air filter becoming clogged and requiring maintenance. 2.The adhesive melter of claim 1, further comprising: a level sensorlocated in said receiving space, said level sensor repeatedly sensing afill level of adhesive located within said receiving space, wherein saidcontroller is configured to actuate said fill system by startingoperation of said fill system when said level sensor senses that thefill level has dropped below a refill threshold and by stoppingoperation of said fill system when said level sensor senses that thefill level has exceeded a full fill threshold.
 3. The adhesive melter ofclaim 2, wherein the level sensor comprises multiple level sensors insaid receiving space.
 4. The adhesive melter of claim 2, wherein saidreceiving space is at least partially defined by a sidewall, and saidlevel sensor further comprises: a plate element; an electrically drivenelectrode located on said plate element; and a ground electrode locatedon said plate element, the ground electrode being electrically connectedto said sidewall such that said sidewall forms at least a portion ofsaid ground electrode, and said ground electrode being electricallyconnected to said electrically driven electrode for measuring adielectric capacitance of air and adhesive between said driven andground electrodes.
 5. The adhesive melter of claim 2, wherein saidcontroller is configured to generate the signal based solely on datareceived from said level sensor.
 6. The adhesive melter of claim 2,wherein the controller is configured to monitor the duration of eachfill system cycle performed by said fill system by: detecting a firsttime when the level sensor senses that the fill level has dropped belowthe refill threshold and a second time when the level sensor senses thatthe fill level has exceeded the full fill threshold; calculating adifference between the first time and the second time, the differencecorresponding to the duration of the selected fill system cycle; andrepeating the detecting and calculating a difference steps for each ofthe fill system cycles.
 7. The adhesive melter of claim 1, wherein saidcontroller is configured to detect the change in the average durationfor the fill system cycles by: identifying a predetermined number ofmost recently calculated average durations for the plurality of the fillsystem cycles, analyzing the predetermined number of most recentlycalculated average durations over time to determine a trend line for themost recently calculated average durations, and calculating a slope ofthe trend line to detect the change in the average duration for the fillsystem cycles.
 8. The adhesive melter of claim 1, wherein the controlleris configured to shut down the fill system if the average duration forthe plurality of fill system cycles exceeds a maximum flow threshold. 9.The adhesive melter of claim 8, wherein said controller is configured togenerate an alert before the average duration for the plurality of fillsystem cycles exceeds the maximum flow threshold to provide a period oftime for maintenance of said exhaust air filter before shut down of thefill system.
 10. The adhesive melter of claim 1, further comprising auser interface in electrical communications with the controller, whereinthe controller is configured to generate the signal by generating analert for emission by the user interface if the detected change exceedsthe maintenance threshold indicative of said exhaust air filter becomingclogged and requiring maintenance.
 11. The adhesive melter of claim 10,wherein the user interface comprises a display, and the display isconfigured to display the alert if the detected change exceeds themaintenance threshold indicative of said exhaust air filter becomingclogged and requiring maintenance.
 12. The adhesive melter of claim 10,wherein the user interface comprises a speaker, and the speaker isconfigured to emit the alert if the detected change exceeds themaintenance threshold indicative of said exhaust air filter becomingclogged and requiring maintenance.
 13. The adhesive melter of claim 10,wherein the controller is configured to continue generating the alertuntil either maintenance is performed on the exhaust air filter or thefill system shuts down.
 14. The adhesive melter of claim 1, wherein thecontroller is further configured to: analyze the duration of each of thefill system cycles to identify outliers; and discard the outliers beforecalculating the average duration for the plurality of the fill systemcycles.
 15. The adhesive melter of claim 1, wherein the controller isfurther configured to: determine that the exhaust air filter has beenmaintained; evaluate a duration of each of the fill system cycles for aninitial time period following maintenance of the exhaust air filteruntil the average duration for a plurality of fill system cyclesstabilizes; and discard the durations of the fill system cycles duringthe initial time period.
 16. The adhesive melter of claim 1, wherein thefill system is at an ambient temperature to maintain the adhesiveparticulate as solid adhesive particulate.
 17. The adhesive melter ofclaim 1, further comprising a heater unit configured to melt the solidadhesive particulate from the receiving space.
 18. The adhesive melterof claim 17, further comprising a reservoir holding the melted adhesivemelted by the heater unit.
 19. The adhesive melter of claim 18, furthercomprising: a dispenser gun configured to discharge the melted adhesiveon a substrate; and a pump configured to deliver the melted adhesivefrom the reservoir to the dispenser gun.
 20. The adhesive melter ofclaim 1, further comprising a cyclonic separator mounted to an inlet ofthe receiving space.